Method for Making a Composite Material Wheel Rim

ABSTRACT

A method for making the composite material wheel rim comprises the steps of: configuring a plurality of inner lining chunks individually to the desired position where the spokes are to be mounted so as to allow the inner lining chunks to be integrated with an inner annular portion of the wheel rim, next, integrating the formed inner annular portion with an outer annular portion of the wheel rim to form a semi-finished wheel rim, and then, creating the requested threaded holes for connecting the spokes in the inner lining chunks of the inner surface of the semi-finished wheel rim subject to the requested amount and angles of the spokes. By the prevent method, the semi-finished wheel rim allows to be drilled threaded holes subject to needs to fit different types of wheel hub units so as to increase the yield rate and reduce the inventory of the wheel rims.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applications Ser. No. 13/602,441 entitled “Composite material wheel rim structure” and filed on Sep. 4, 2012.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for making the composite material wheel rim, in particular, to a method of making the wheel rim allowing to be drilled threaded holes after it is fully formed according to the spoke mount of the requested wheel hub and the assembled angle of each spoke to fit different types of wheel hub units so as to increase the yield rate and reduce the inventory of the wheel rims.

2. Description of the Prior Art

To equalize the spoke tension of a bicycle wheel unit, generally, the wheel unit is radially arranged with a plurality of spokes for connecting the wheel rim of the wheel unit and the wheel hub. Not all the assembled angles of the spokes are the same, so that the position of connecting each spoke at the inner surface of the wheel rim needs to be drilled the threaded hole in compliance with the orientation angle of each spoke to fit and connect each spoke. A prior art method of making a wheel rim, such as the method disclosed in US 2007/0102995 (hereafter the prior art case), involves: (a) forming a annular metallic rim member (annular metallic rim member 22); (b) bonding a plurality of reinforcement members (reinforcement members 23) providing pre-formed threaded holes with different angles (threaded bore 23 c) to the inner surface of the annular metallic rim member (annular metallic rim member 22) by adhesive, and the bonded positions of the reinforcement members and the angle of individual threaded hole which each bonded position requires are configured according to the requested spoke amount of the wheel hub and the orientation angles of the discrete spokes; (c) using the adhesive attachment materials or sheets (adhesive attachment materials or sheets 24) to overlie all of the plurality of reinforcement members so as to integrate the reinforcement members with the annular metallic rim member; (d) using a drill to individually drill the opening of the pre-formed threaded hole (threaded bore 23 c) in each reinforcement member covered by the adhesive attachment materials or sheets, such that the wheel rim disclosed in the prior art case is completed.

However, the prior art case described above has deficiencies in manufacturing as follows:

-   -   (I) The reinforcement members (reinforcement members 23)         disclosed in the prior art case involve diverse reinforcement         members with various angles of threaded holes, so that the         diverse reinforcement members need to be separated from one         another carefully, otherwise it is easy to be mixed and result         in wrongly using, and thus, the pressure of the storage         administrator in inventory management may increase when stock         preparation.     -   (II) Basically, different threaded holes provide different spoke         assembled angles so that each reinforcement member with a         threaded hole should be placed at an accurate position fitting         the orientation angle of the spoke mating with it when the wheel         rim is completely formed; if one of them is arranged wrongly,         the wheel rim may become a defective unit which can not be used;         or, the reinforcement member is disposed correctly, however, it         is positioned in an inaccurate direction, and that causes the         threaded hole to provide an incorrect angle, so that the wheel         rim also becomes a defective unit; therefore, the prior art case         has the drawback of high product defect rate.     -   (III) The wheel rim disclosed in the prior art case can only be         applied to the type of wheel hub which the wheel rim allows to         mate with, that is, other types of wheel hubs can not fit such a         wheel rim, and thus, different types of wheel rims need to be         stocked separately so that the inventory cost of the wheel rims         is increased.

SUMMARY OF THE INVENTION

It is a primary object of the present invention to provide a method for making the composite material wheel rim, and the method involves configuring and securing a plurality of inner lining chunks for connecting the spokes to the inside of the wheel rim, wherein the plurality of inner lining chunks provide no pre-drilled threaded holes before fixed inside the wheel rim, and after a semi-finished wheel rim is fully formed, the semi-finished wheel rim is allowed to be drilled threaded holes according to the amount of the spokes of the wheel hub that the consumer requests and the assembled angle of each spoke.

In order to achieve the aforesaid objective, the present invention is characterized by disposing a plurality of inner lining chunks without pre-drilled threaded holes individually to the desired positions where the spokes are to be mounted so as to allow the inner lining chunks to be integrated with an inner annular portion of the wheel rim, next, integrating the formed inner annular portion with an outer annular portion of the wheel rim to form a semi-finished wheel rim, and then, creating the requested threaded holes for connecting the spokes in the inner lining chunks of the inner surface of the semi-finished wheel rim subject to the requested amount of the spokes and the assembled angle of each spoke. By the prevent method, the fully-formed semi-finished wheel rim allows to be drilled threaded holes subject to the spoke mount of the requested wheel hub to fit different types of wheel hub units so as to increase the yield rate and reduce the inventory of wheel rims.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the present invention may be more fully understood, a preferred embodiment thereof will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a stereogram of the wheel rim unit according to the embodiment of the present invention.

FIG. 2 is a front view of the wheel rim unit according to the embodiment of the present invention.

FIG. 3 is a diagram showing the process steps involved in making the composite material wheel rim according to the embodiment of the present invention.

FIG. 4 is a stereogram showing the appearance of the semi-finished wheel rim according to the embodiment of the present invention.

FIG. 5 is a front cross-sectional view of the wheel rim unit according to the embodiment of the present invention.

FIG. 6 is a first partially enlarged view of FIG. 4.

FIG. 7 is a second partially enlarged view of FIG. 4.

FIG. 8 is a side cross-sectional view of the wheel rim unit according to the embodiment of the present invention.

FIG. 9 is an enlarged view of A shown in FIG. 8.

FIG. 10 is an enlarged view of B shown in FIG. 8.

FIG. 11 is an enlarged view of C shown in FIG. 8.

FIG. 12 is an enlarged view of D shown in FIG. 8.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The means for achieving the aforesaid objective and the functions of the present invention will become apparent from the following description, taken in connection with the accompanying drawings, wherein a preferred embodiment of the present invention is disclosed.

Referring to FIG. 1 to FIG. 3, the bicycle wheel unit 1 includes a wheel rim 10, a wheel hub 11 and a plurality of spokes 12, wherein the wheel hub 11 is arranged to the center of the wheel rim 10; moreover, the spoke 12 has one end connected with the inner surface of the wheel rim 10 and the other end connected with the outer edges of both ends of the wheel hub 11. A method for making the composite material wheel rim 10 disclosed in the present invention, as shown in FIG. 3, comprises the steps of:

-   -   (a) placing a plurality of inner lining chunks 14, which are         metallic material and provide no pre-drilled threaded holes, in         a first mold, which is used for forming an inner annular portion         13 of the wheel rim 10, according to the desired position where         each spoke 12 is to be mounted, next laminate-stacking carbon         fiber cloth 15 such that the inner lining chunks 14 are encased         in, and then processing by thermally pressing and hardening so         as to form the inner annular portion 13 of the wheel rim 10, as         shown in FIG. 4, wherein, the plurality of inner lining chunks         14 are fixed within the inner annular portion 13.     -   (b) placing the fully-formed inner annular portion 13 made in         step (a) in a second mold, which is used for forming an outer         annular portion 16 of the wheel rim 10, stacking carbon fiber         cloth 15 onto the outer side of the inner annular portion 13         after aligning the alignment point, and processing the         combination of the inner annular portion 13 and the outer         annular portion 16 by thermally pressing and hardening so as to         form a semi-finished wheel rim 17.     -   (c) using a drilling tool 20 and a thread tapping tool 30 to         create the requested tapped holes in the inner lining chunks 14         inside the semi-finished wheel rim 17 so as to form threaded         holes 18 subject to the amount of the spokes 12 configured to         the arranged wheel hub 11 and the assembled angle of each spoke         12, wherein the threaded holes 18 are drilled and tapped from         the inner surface of the semi-finished wheel rim 17 toward the         inner lining chunks 14, such that a wheel rim 10 is fully formed         and the manufacturing process of the wheel rim 10 is completed.

The amount of the threaded holes and the drilled angle of each threaded hole 18 may be altered to correspond with the amount of the spokes 12 of the aforementioned wheel hub 11 and the assembled angle of each spoke 12. Referring to FIG. 5 to FIG. 8, one end of the spoke 12 is provided with a first end 120 connected with the wheel rim 10 and the other end of the spoke 12 provides a second end 121 secured to a fixed protruding member 110 arranged to the outer edges of both ends of the wheel hub 11; wherein, the first end 120 has an outward-enlarged head 123; after the spoke 12 is inserted through a hollow adjusting element 122, the adjusting element 122 is confined to the spoke 12 by the head 123. The outer wall of the adjusting element 122 provides an external thread section 124 allowed to be screwed to the threaded hole 18, as shown in FIG. 9 to FIG. 12, so that the first end 120 of the spoke 12 is connected with the threaded hole 18 of the wheel rim 10; moreover, the adjusting element 122 is allowed to be adjusted axially in the interior of the threaded hole 18 so as to adjust the pulling force of the spoke 12.

After being fully formed, the semi-finished wheel rims 17 may be stored, and then, according to the amount of the spokes 12 of the wheel hub 11 that the consumer requests and the assembled angle of each spoke 12, the inner lining chunks 14 inside the semi-finished wheel rim 17 are individually drilled a hole by the drilling tool 20 and each hole is tapped threads by the thread tapping tool 30 so as to form threaded holes 18, and thus the wheel rim 10 is fully formed and the manufacturing process of the wheel rim 10 is completed. The threaded holes drilling may employ the laser to mark the positions of the threaded holes and use the NC or CNC machine tool to drill holes and tap threads so as not only to enable the space between the threaded holes and the angle of each hole to be drilled precisely but also to permit the numerous holes to be drilled at a time.

The method for making the composite material wheel rim disclosed in the present invention provides advantages and functions as follows:

-   -   (I) Before integrated with inner annular portion 13, each inner         lining chunk 14 provides no pre-drilled threaded hole; that is,         the inner lining chunks 14 are individually drilled a hole and         tapped threads after the semi-finished wheel rim 17 is formed,         and moreover, the threaded holes are created subject to the         spoke 12 amount of the wheel hub 11 that the consumer requests         and the assembled angle of each spoke 12; consequently, the         manufacturers have no needs to stock different inner lining         chunks 14 with different angles of threaded holes or different         types of wheel rims for different types of wheel hubs, so that         the produce cost and the inventory cost can be reduced so as to         increase the business competitive advantage.     -   (II) The method disclosed in the present invention allows to         avoid not only the problem in storage management and the         complexity and difficulty of production process but also the         errors of wrongly arranging the reinforcement members to the         rims occurring in the aforesaid prior art case; besides, the         present method also allows to avoid the carelessness in income         quality control (IQC), in-process quality control (IPQC), and         outgoing quality control (OQC) so as to reduce the working hours         for inspection, and thus, the production process is allowed to         be managed effectively.     -   (III) The method disclosed in the present invention allows not         only reduce the working hours and the burden of the operation         personnel but also increase the product accuracy and the yield         rate (non-defective unit rate) so as to enhance the products         competitive advantage.     -   (IV) The drilling of threaded holes disclosed in the present         invention may employ the laser to mark the positions of holes         and use the NC or CNC machine tool to drill holes and tap         threads, so that the space between the threaded holes and the         angle of each drilled hole can be extremely precise to meet the         product standard, and besides, employing such tools allows the         numerous holes to be drilled at a time.     -   (V) The threaded holes disclosed in the present invention are         created after the semi-finished wheel rim 17 is formed, so that         each threaded hole provides extremely accurate position and         angle so as to allow the adjusting element 122 of each spoke 12         to be screwed to the inner lining chunk 14 more tightly without         being loose or dropping off to ensure the products safety in use         to benefit the riders.

It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing from the spirit and scope thereof. The variations and modifications as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth. 

What is claimed is:
 1. A method for making the composite material wheel rim, comprising the steps of: (a) in a first mold used for forming an inner annular portion of the wheel rim, placing a plurality of inner lining chunks individually to the desired position where each spoke is to be mounted, and then laminate-stacking carbon fiber cloth to enable the plurality of inner lining chunks to be encased in so as to process to form the inner annular portion of the wheel rim; (b) placing the formed inner annular portion in a second mold used for forming an outer annular portion of the wheel rim, stacking carbon fiber cloth onto the outer side of the inner annular portion after aligning the alignment point, and processing the combination of the inner annular portion and the outer annular portion so as to form a semi-finished wheel rim; (c) according to the spoke amount of the arranged wheel hub and the assembled angle of each spoke, drilling and tapping the requested holes in the inner lining chunks of the inner surface of the semi-finished wheel rim which is to be connected with the arranged wheel hub so as to form threaded holes, and thus the wheel rim is completely formed.
 2. The method for making the composite material wheel rim as claimed in claim 1, wherein the amount and the drilled angles of the threaded holes are allowed to be adjusted to correspond with the amount of the spokes of the wheel hub and the assembled angle of each spoke.
 3. The method for making the composite material wheel rim as claimed in claim 2, wherein the inner lining chunks are metallic material.
 4. The method for making the composite material wheel rim as claimed in claim 3, wherein one end of the spoke is provided with a first end connected with the wheel rim and the other end of the spoke provides a second end secured to a fixed protruding member arranged to the outer edge of the wheel hub; wherein, the first end has an outward-enlarged head, and after the spoke is inserted through a hollow adjusting element, the adjusting element is confined to the spoke by the head; wherein, the outer wall of the adjusting element provides an external thread section allowed to be screwed to the threaded hole.
 5. The method for making the composite material wheel rim as claimed in claim 4, wherein the threaded holes are formed at a time by employing the laser to mark the positions of holes and using NC machine tool to drill holes and tap threads. 